On the mechanism of fatigue failure in the superlong life regime (N>107 cycles). Part II: influence of hydrogen trapped by inclusions

Abstract

High cycle fatigue fracture surfaces of specimens in which failure was initiated at a subsurface inclusion were investigated by atomic force microscopy and by scanning electron microscopy. The surface roughness Ra increased with radial distance from the fracture origin (inclusion) under constant amplitude tension–compression fatigue, and the approximate relationship: Ra ≅ CΔK 2I holds. At the border of a fish‐eye there is a stretched zone. Dimple patterns and intergranular fracture morphologies are present outside the border of the fish‐eye. The height of the stretch zone is approximately a constant value around the periphery of the fish‐eye. If we assume that a fatigue crack grows cycle‐by‐cycle from the edge of the optically dark area (ODA) outside the inclusion at the fracture origin to the border of the fish‐eye, we can correlate the crack growth rate da/dN, stress intensity factor range ΔKI and Ra for SCM435 steel by the equation and by da/dN proportional to the parameter Ra .Integrating the crack growth rate equation, the crack propagation period Np2 consumed from the edge of the ODA to the border of the fish‐eye can be estimated for the specimens which failed at Nf > 107. Values of Np2 were estimated to be ∼1.0 × 106 for the specimens which failed at Nf ≅ 5 × 108. It follows that the fatigue life in the regime of Nf >107 is mostly spent in crack initiation and discrete crack growth inside the ODA.